Intercooler go BOOM???
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Junior User
Joined: Jun 2005
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From: Spruce Grove,AB, Canada
Intercooler go BOOM???
I know some of the others around here have had this happen to their trucks and now my 03 6L has finally done it, the passanger side of the cooler blew off while climbing a long hill on the highway. Just wondering if anybody managed to get this fixed under warranty. Is it true this was a problem that was rectified by a redesigned cooler.
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They are covered by the diesel engine warranty. I actually replaced 2 of them last week. I found that one truck was over-boosting, but I couldn't figure out why the other one blew. I don't know anything of a redesigned cooler.
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From: Laporte , Indiana
Many have fixed this themselves. I believe the ones that continue to blow off tubes have an overboost problem that their dealer needs to figure out. Some have driven sheet metal screws through the clamps boot and intake. However this could cause warranty issues. Some on here have created a bracket that mounts around the silver down tube and bolts to the alternator bracket. I am going to do this option as it seems to be pretty practical. Without sacrificing your warranty.
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From: Milky Way Galaxy
Several of us with the '03-early '04 engines had the hose blow-off because of improperly torqued clamps or broken clamps. The broken ones were almost always the older clamps that had 2 holes in the band. They would flex up and down with the boost until they finally snapped. There was also a problem with certain hoses. I think it may have been the black ones and possibly some of the blue ones. There was a recall on them if I'm not mistaken. That may be the redesign in '03-'04's you're talking about.
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From: Spruce Grove,AB, Canada
I understand what you are saying about the Tubes, but that is not my Issue. I had the InterCooler side tank Blow!! The side tank seperates from the finned part of the Cooler. I think that GuyCanada understood my issue, that he has repaired a few this week. I was supriesd that it was the InterCooler that blew & not the Hose.
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From: Milky Way Galaxy
I was way off on that one.
I haven't heard about about any actually blowing apart like that. I did however have my truck in the shop not to long ago for yet another oil leak. While my truck was there the service adviser had them check my cooling system along with a bunch of other problems he had been seeing on the '03-'04 6.0's lately. Well, lo and behold the intercooler was leaking (news to me) and had to be replaced. All of it was done under warranty. So I'm inclined to think they do have a problem. I just hadn't heard of them actually blowing apart.
I haven't heard about about any actually blowing apart like that. I did however have my truck in the shop not to long ago for yet another oil leak. While my truck was there the service adviser had them check my cooling system along with a bunch of other problems he had been seeing on the '03-'04 6.0's lately. Well, lo and behold the intercooler was leaking (news to me) and had to be replaced. All of it was done under warranty. So I'm inclined to think they do have a problem. I just hadn't heard of them actually blowing apart.
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From: 3rd Rock
Blew the end off of my 03, they fixed it no problem.
That was a long time ago......
Are you running a tuner?
That was a long time ago......
Are you running a tuner?
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Junior User
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From: Spruce Grove,AB, Canada
Yes I have a tuner ( it was on the 60HP tune), and I think I'll pull my trailor with only the stock tune from now on.
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From: Spruce Grove,AB, Canada
Well I got the truck back from the dealer and it has a brand new turbo and a new intercooler. I never had a chance to talk to the tech, but the service writer said he was told that the turbo went first then over boosted and blew the cooler. I don't really by that I think they just wanted to get that original 03 turbo so they could have all the cool whistle the 03 make. Anybody know if the new turbos are better or do they just not make as much boost.
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From: Spruce Grove,AB, Canada
[QUOTE=Tim Lamkin]No need to do that just roll out of the throttle......[
/QUOTE]
I did notice that the boosting issue could be a result of towing with the cruise control and towing button on. This makes big boost because the trans doesn't shift down and the boost goes up to make power to climb hills on the highway, I've seen it at 35psi before.
/QUOTE]
I did notice that the boosting issue could be a result of towing with the cruise control and towing button on. This makes big boost because the trans doesn't shift down and the boost goes up to make power to climb hills on the highway, I've seen it at 35psi before.
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From: 3rd Rock
An 1/8 of an inch out of the loud pedal will make a huge difference in boost...going up a hill...IMO big loads I would NEVER use cruise control...my right foot is better educated ...IMO
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From: Spruce Grove,AB, Canada
Originally Posted by Tim Lamkin
An 1/8 of an inch out of the loud pedal will make a huge difference in boost...going up a hill...IMO big loads I would NEVER use cruise control...my right foot is better educated ...IMO
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From: waynesville, mo.
not only can the variable vanes in the turbo stick causing no power, they can stick at full boost,causing head gasket problems and intercooler explosions. As a tech, the first thing I have to do is determine which of the two caused it.(turbo or tuner)
Last edited by vloney; Jul 7, 2006 at 09:01 PM. Reason: incomplete posting